Industrial Visit Report-KEL

CHAPTER-3

ORGANIZATON-KEL

3.1 ORGANIZATION STUDY-KEL

The Kerala Electrical and Allied Engineering Co Ltd., popularly known as KEL was established
in 1964 in state of Kerala India, and is fully owned by the State Government. As a company
engaged in multifarious activities, KEL has gradually their manufacturing base strategically to
reach a wider domestic and overseas market.

With a manpower base of 1500; this includes more than 250 highly qualified and well trained
engineers, KEL is one of the biggest public sector companies in the state. The company has four
manufacturing units, located in various districts of the state.

As a company in tune with modern technology, KEL is associated with reputed overseas
manufacturers who are experts in their respective fields.

Their products are marketed through an all-India network of marketing and sales service officers
in all the metro cities. These offices provide all services to the sales and marketing team to
guarantee complete customer satisfaction.

KEL Alternators type KELA 18135 are designed for power supply (with drive from the axle) in
the air conditioned coaches of Indian Railways. The alternator with associated regulator
rectifier unit delivers 18kw power (at a constant voltage of 135+ or-5% from no load to 133 A
load) at all train speeds above about 50 KM PH.

The system consists of a Brushless inductor type alternator is completely static regulator-rectifier
unit. The alternator is completely devoid of any type of moving coils or sliding contacts and this
ensures a trouble free operation without practically any maintenance.

The regulator- rectifier unit makes use of silicon dioxides, transformers and Magnetic
Amplifier. All the components used in the rectifier-regulator unit are transistors and thermistors
tailor made requirement of the hazardous application to which they are put in Rolling Stock. As
such the reliability of KEL generating system is high.

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Industrial Visit Report-KEL

3.2 Process Flow of Sand Preparation & Moulding

The 2.5 to 4.5 KW alternators and axle pulleys are sent to old machine shop, lathe parts are send
to QETCOS.

The different parts made are:

25 KW Alternator pulley
4,5 KW Alternator pulley
Lathe parts like saddle, lathe bed, tail stock and head stock
End plate, End shield
2.5 and 4.5 KW axle pulley

3.3 OLD MACHINE SHOP

The old machine shop was the first machine shop set up and used when the company started
functioning. Now this shop is used for doing basic operations such as construction of
regulator boxes, alternator suspension boxes, bearing plates etc., before being sent to the
newly set up machine shop.

The basic operations are going on here are:

The making of suspension box foe alternator

Making of regulator boxes
Making of fan covers, bearing covers etc.,
Operations like facing, drilling, tapping and keyway cutting of pulley.

3.3.1 Process Flow

The 25 KW and 4.5 KW pulleys that come from the foundry section are fixed on the lathe and
facing is done. Holes are then drilled by the drilling machine to make provision for nuts and bolts
to be inserted for joining rigidly the top and bottom parts of the axle pulleys. Six pair of nuts and
bolts are used to join them together.

The end plate is directly taken from foundry; further operations are done in new machine shop.
The 4.5 and 25 KW alternator pulleys are subjected to facing in the old machine shop and also
key way cutting is done using a milling machine with vertical stroke.

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Industrial Visit Report-KEL

3.4 NEW MACHINE SHOP

Operations are done on:

Turret Lathe
Central Lathes
Cutting Machine
Milling Machine
3.4.1 Activities
Alternator assembly (Winding, Rotor Assembly etc.)
Regular box assembly
Testing
Painting
Dispatch

3.4.2 Finished Products

4.5 and 25 KW Alternators

Regulators
Lathe Parts

3.5 KEL PICS

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Industrial Visit Report-KEL

Fig 3.1 ALTERNATOR PART

Fig 3.2 ALTERNATOR

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Industrial Visit Report-KEL

Fig 3.3 TRANFORMER FABRICATION

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Mechanical Engineering, SBCE, Pattoor